US20100047586A1 - Modified ethylene-vinyl alcohol copolymer, gas barrier resin, and molded article of the same - Google Patents
Modified ethylene-vinyl alcohol copolymer, gas barrier resin, and molded article of the same Download PDFInfo
- Publication number
- US20100047586A1 US20100047586A1 US12/485,598 US48559809A US2010047586A1 US 20100047586 A1 US20100047586 A1 US 20100047586A1 US 48559809 A US48559809 A US 48559809A US 2010047586 A1 US2010047586 A1 US 2010047586A1
- Authority
- US
- United States
- Prior art keywords
- gas barrier
- resin
- vinyl alcohol
- set forth
- group
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 108
- 239000011347 resin Substances 0.000 title claims abstract description 108
- 230000004888 barrier function Effects 0.000 title claims abstract description 85
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 title claims abstract description 69
- RZXDTJIXPSCHCI-UHFFFAOYSA-N hexa-1,5-diene-2,5-diol Chemical class OC(=C)CCC(O)=C RZXDTJIXPSCHCI-UHFFFAOYSA-N 0.000 title claims abstract description 51
- -1 methacryloxy group Chemical group 0.000 claims abstract description 32
- 150000007970 thio esters Chemical group 0.000 claims abstract description 4
- 125000003396 thiol group Chemical group [H]S* 0.000 claims abstract description 4
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims abstract description 4
- 229920001971 elastomer Polymers 0.000 claims description 35
- 239000000806 elastomer Substances 0.000 claims description 32
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 24
- 125000000217 alkyl group Chemical group 0.000 claims description 24
- 229920000570 polyether Polymers 0.000 claims description 24
- 229910000077 silane Inorganic materials 0.000 claims description 23
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 21
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 10
- 150000008065 acid anhydrides Chemical class 0.000 claims description 10
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 7
- 239000004952 Polyamide Substances 0.000 claims description 5
- 239000004793 Polystyrene Substances 0.000 claims description 5
- 229920001328 Polyvinylidene chloride Polymers 0.000 claims description 5
- 150000001993 dienes Chemical class 0.000 claims description 5
- 229920002647 polyamide Polymers 0.000 claims description 5
- 229920000515 polycarbonate Polymers 0.000 claims description 5
- 239000004417 polycarbonate Substances 0.000 claims description 5
- 229920000728 polyester Polymers 0.000 claims description 5
- 229920000098 polyolefin Polymers 0.000 claims description 5
- 229920006124 polyolefin elastomer Polymers 0.000 claims description 5
- 229920002223 polystyrene Polymers 0.000 claims description 5
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 5
- 239000004800 polyvinyl chloride Substances 0.000 claims description 5
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 4
- 239000004814 polyurethane Substances 0.000 claims description 4
- 229920002635 polyurethane Polymers 0.000 claims description 4
- 125000001931 aliphatic group Chemical group 0.000 claims description 3
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 claims description 3
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 3
- 229940124530 sulfonamide Drugs 0.000 claims 1
- 150000003456 sulfonamides Chemical class 0.000 claims 1
- 238000005452 bending Methods 0.000 abstract description 23
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 abstract description 4
- 239000005977 Ethylene Substances 0.000 abstract description 4
- QAZLUNIWYYOJPC-UHFFFAOYSA-M sulfenamide Chemical compound [Cl-].COC1=C(C)C=[N+]2C3=NC4=CC=C(OC)C=C4N3SCC2=C1C QAZLUNIWYYOJPC-UHFFFAOYSA-M 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 38
- 239000000203 mixture Substances 0.000 description 13
- 230000000052 comparative effect Effects 0.000 description 8
- 238000002844 melting Methods 0.000 description 8
- 230000008018 melting Effects 0.000 description 8
- 238000000034 method Methods 0.000 description 8
- 0 [1*]COC(C)CC Chemical compound [1*]COC(C)CC 0.000 description 7
- 229920001577 copolymer Polymers 0.000 description 6
- 230000035699 permeability Effects 0.000 description 6
- 239000000853 adhesive Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- BTANRVKWQNVYAZ-UHFFFAOYSA-N CCC(C)O Chemical compound CCC(C)O BTANRVKWQNVYAZ-UHFFFAOYSA-N 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 3
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- 229920002725 thermoplastic elastomer Polymers 0.000 description 3
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 2
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 2
- CTKINSOISVBQLD-UHFFFAOYSA-N Glycidol Chemical compound OCC1CO1 CTKINSOISVBQLD-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000013065 commercial product Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000012948 isocyanate Substances 0.000 description 2
- 150000002513 isocyanates Chemical class 0.000 description 2
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- WBIQQQGBSDOWNP-UHFFFAOYSA-N 2-dodecylbenzenesulfonic acid Chemical compound CCCCCCCCCCCCC1=CC=CC=C1S(O)(=O)=O WBIQQQGBSDOWNP-UHFFFAOYSA-N 0.000 description 1
- DCQBZYNUSLHVJC-UHFFFAOYSA-N 3-triethoxysilylpropane-1-thiol Chemical compound CCO[Si](OCC)(OCC)CCCS DCQBZYNUSLHVJC-UHFFFAOYSA-N 0.000 description 1
- UUEWCQRISZBELL-UHFFFAOYSA-N 3-trimethoxysilylpropane-1-thiol Chemical compound CO[Si](OC)(OC)CCCS UUEWCQRISZBELL-UHFFFAOYSA-N 0.000 description 1
- XDLMVUHYZWKMMD-UHFFFAOYSA-N 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C(C)=C XDLMVUHYZWKMMD-UHFFFAOYSA-N 0.000 description 1
- KBQVDAIIQCXKPI-UHFFFAOYSA-N 3-trimethoxysilylpropyl prop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C=C KBQVDAIIQCXKPI-UHFFFAOYSA-N 0.000 description 1
- SFDUJXRGJSADCD-UHFFFAOYSA-N CCOCCCCS Chemical compound CCOCCCCS SFDUJXRGJSADCD-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical group OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 1
- 101000837805 Homo sapiens Testis-expressed protein 44 Proteins 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 102100028514 Testis-expressed protein 44 Human genes 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 150000005215 alkyl ethers Chemical class 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000003712 anti-aging effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000009954 braiding Methods 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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- 238000000576 coating method Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
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- 238000004132 cross linking Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 229940060296 dodecylbenzenesulfonic acid Drugs 0.000 description 1
- FWDBOZPQNFPOLF-UHFFFAOYSA-N ethenyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C=C FWDBOZPQNFPOLF-UHFFFAOYSA-N 0.000 description 1
- 238000013213 extrapolation Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000007429 general method Methods 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920000259 polyoxyethylene lauryl ether Polymers 0.000 description 1
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- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 1
- 229960001755 resorcinol Drugs 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 125000003808 silyl group Chemical group [H][Si]([H])([H])[*] 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
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- 238000003786 synthesis reaction Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 125000005369 trialkoxysilyl group Chemical group 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2597/00—Tubular articles, e.g. hoses, pipes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60C—VEHICLE TYRES; TYRE INFLATION; TYRE CHANGING; CONNECTING VALVES TO INFLATABLE ELASTIC BODIES IN GENERAL; DEVICES OR ARRANGEMENTS RELATED TO TYRES
- B60C5/00—Inflatable pneumatic tyres or inner tubes
- B60C5/12—Inflatable pneumatic tyres or inner tubes without separate inflatable inserts, e.g. tubeless tyres with transverse section open to the rim
- B60C5/14—Inflatable pneumatic tyres or inner tubes without separate inflatable inserts, e.g. tubeless tyres with transverse section open to the rim with impervious liner or coating on the inner wall of the tyre
- B60C2005/145—Inflatable pneumatic tyres or inner tubes without separate inflatable inserts, e.g. tubeless tyres with transverse section open to the rim with impervious liner or coating on the inner wall of the tyre made of laminated layers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L11/00—Hoses, i.e. flexible pipes
- F16L11/04—Hoses, i.e. flexible pipes made of rubber or flexible plastics
- F16L2011/047—Hoses, i.e. flexible pipes made of rubber or flexible plastics with a diffusion barrier layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
- Y10T428/31573—Next to addition polymer of ethylenically unsaturated monomer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31909—Next to second addition polymer from unsaturated monomers
- Y10T428/31913—Monoolefin polymer
Definitions
- the present invention relates to a modified ethylene-vinyl alcohol copolymer, more particularly relates to a gas barrier resin comprising the modified ethylene-vinyl alcohol copolymer and a molded article prepared from the same, particularly a pneumatic tire and a hose.
- Ethylene-vinyl alcohol copolymers have superior gas barrier property, but have the defect that they are interior in bending fatigue resistance. To improve on this, there is known a method of modifying an ethylene-vinyl alcohol copolymer with an epoxy compound. See Japanese Unexamined Patent Publication No. 2003-231715.
- the present invention addresses the matter of improving the drawback of an ethylene-vinyl alcohol copolymer, that is, the bending fatigue resistance, without reducing gas barrier property and heat resistance.
- the present invention is a modified ethylene-vinyl alcohol copolymer comprising 20 to 50 percent by mole of a structural unit (1) expressed by the following formula (1):
- n indicates an integer of 2 to 7
- m indicates an integer of 10 to 20
- R 1 indicates a C 1 to C 20 aliphatic hydrocarbon group or aliphatic hydrocarbon group substituted with a mercapto group, thioester group, sulfenamide, vinyl group, methacryloxy group, or acryloxy group.
- the modified ethylene-vinyl alcohol copolymer is preferably prepared by melt blending an ethylene-vinyl alcohol copolymer with an alkyl polyether silane expressed by the following formula (4):
- R 2 is a methyl group or ethyl group
- R 1 , n, and m are the same as above.
- the present invention is a gas barrier resin comprising the modified ethylene-vinyl alcohol copolymer.
- the gas barrier resin preferably contains 100 parts by weight of the modified ethylene-vinyl alcohol copolymer and 5 to 120 parts by weight of a soft resin modified by an acid anhydride.
- the present invention is a molded article comprising the gas barrier resin.
- the present invention is a laminate comprising a layer of the gas barrier resin and a layer of a resin and/or elastomer other than the gas barrier resin.
- the resin other than the gas barrier resin is preferably at least one resin selected from the group consisting of a polyolefin, polyamide, polyester, polystyrene, polyurethane, poly(vinylidene chloride), poly(vinyl chloride), polyacrylonitrile, and polycarbonate.
- the elastomer other than the gas barrier resin is preferably selected from the group consisting of a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer.
- the present invention is a pneumatic tire comprising the gas barrier resin or the laminate as an air barrier layer.
- the present invention is a hose comprising the gas barrier resin or the laminate as an air barrier layer.
- the modified ethylene-vinyl alcohol copolymer of the present invention is superior in gas barrier property, heat resistance, and bending fatigue resistance. Because the modified ethylene-vinyl alcohol copolymer of the present invention is superior in gas barrier property, heat resistance, and bending fatigue resistance, it may be suitably used as a gas barrier resin and in molded articles, particularly pneumatic tires and hoses, requiring a gas barrier property.
- the modified ethylene-vinyl alcohol copolymer of the present invention comprises a structural unit (1), a structural unit (2), and a structural unit (3).
- the structural unit (1) is a so-called ethylene unit expressed by the following formula (1):
- the structural unit (2) is a so-called vinyl alcohol unit expressed by the following formula (2):
- the structural unit (3) is a structural unit, containing an alkyl polyether silyl group in the side chain, expressed by the following formula (3):
- n indicates an integer of 2 to 7, preferably an integer of 4 to 6, more preferably 5
- m indicates an integer of 10 to 20, preferably an integer of 11 to 18, more preferably an integer of 12 to 16
- R 1 indicates an aliphatic hydrocarbon group having one to 20 carbon atoms, preferably 2 to 10 carbon atoms, more preferably 3 to 5 carbon atoms.
- R 1 may contain a mercapto group, thioester group, sulfenamide, vinyl group, methacryloxy group, or acryloxy group.
- R 1 is particularly preferably 3-mercaptopropyl.
- the modified ethylene-vinyl alcohol copolymer comprises 20 to 50 percent by mole, preferably 30 to 45 percent by mole, more preferably 35 to 40 percent by mole of the structural unit (1). If the content of the structural unit (1) is too low, there is a tendency for the bending fatigue resistance to be insufficient, and if too high on the other hand, there is a tendency for gas barrier property to become insufficient.
- the modified ethylene-vinyl alcohol copolymer comprises 0.01 to 1 percent by mole, preferably 0.03 to 0.5 percent by mole, more preferably 0.05 to 0.25 percent by mole of the structural unit (3). If the content of the structural unit (3) is too low, there is a tendency for the bending fatigue resistance to be insufficient, and if too high on the other hand, there is a tendency for gas barrier property to become insufficient.
- the modified ethylene-vinyl alcohol copolymer preferably comprises 49.9 to 79 percent by mole of structural unit (2).
- the modified ethylene-vinyl alcohol copolymer may comprise structural units other than structural unit (1), structural unit (2), and structural unit (3) within a scope that does not hamper the effect of the present invention. Note that, the content of each structural unit in the modified ethylene-vinyl alcohol copolymer may be measured by NMR.
- the modified ethylene-vinyl alcohol copolymer is an ethylene-vinyl alcohol copolymer comprising the structural unit (1) and structural unit (2) modified by an alkyl polyether silane shown in formula (4):
- R 2 indicates a methyl group or ethyl group
- R 1 , n, and m are the same as above.
- the modified ethylene-vinyl alcohol copolymer may be prepared by melt blending the ethylene-vinyl alcohol copolymer and the alkyl polyether silane shown in formula (4).
- the alkyl polyether silane shown in formula (4) reacts by condensation with the OH groups of the ethylene-vinyl alcohol copolymer whereby the alcohol is removed and the structural unit (3) is formed.
- the blend ratio of the ethylene-vinyl alcohol copolymer and the alkyl polyether silane shown in formula (4) is, based on 100 moles of the total of the structural unit (1) and structural unit (2) of the ethylene-vinyl alcohol copolymer, 0.01 to 1 mole of the alkyl polyether silane shown in formula (4).
- the conditions for melt blending are not particularly limited so long as they are conditions in which the ethylene-vinyl alcohol copolymer and the alkyl polyether silane shown in formula (4) react to form the structural unit (3), but for example a twin screw extruder may be used for processing at 200 to 270° C. for 1 to 5 minutes.
- a commercial product may be used for the alkyl polyether silane shown in formula (4) or one may be synthesized.
- An example of a commercial product is the VP Si363 made by Evonik Degussa. Synthesis may be performed as follows. Inside a reaction container, a silane compound having a trialkoxysilyl group (for example, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane, vinyltriethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryioxypropyltriethoxysilane, 3-acryloxypropyltrimethoxysilane, and 3-acryloxytriethoxysilane) is added, dodecylbenzenesulfonic acid or other acid catalyst is added, and further 2 equivalents by mole of a polyoxyethylene alkyl ether (for example, polyoxyethylene lauryl ether, polyoxyethylene cetyl ether, polyoxyethylene
- the gas barrier resin of the present invention comprises the modified ethylene-vinyl alcohol copolymer.
- the gas barrier resin of the present invention may be comprised of only the modified ethylene-vinyl alcohol copolymer, however, it may contain other substances within a scope that does not hamper the effect of the present invention.
- the gas barrier resin of the present invention may be a mixture comprising, other than the modified ethylene-vinyl alcohol copolymer, an acid anhydride modified soft resin (hereinafter also referred to simply as a “modified soft resin”). That is, the gas barrier resin of the present invention may be a mixture of a modified ethylene-vinyl alcohol copolymer and modified soft resin. The inclusion of modified soft resin can further improve the bending fatigue resistance.
- the amount of the modified soft resin blended is, preferably, 5 to 120 parts by weight based on 100 parts by weight of the modified ethylene-vinyl alcohol copolymer. If the amount of the modified soft resin is too low, the improvement effect on the bending fatigue resistance will be lower, and if on the other hand, the amount of the modified soft resin is too high, there is a tendency for gas barrier property to become insufficient.
- the mixture of the modified ethylene-vinyl alcohol copolymer and the modified soft resin is preferably a melt blend of the modified ethylene-vinyl alcohol copolymer and the modified soft resin.
- the modified ethylene-vinyl alcohol copolymer and modified soft resin may be melt blended at a temperature greater than their melting temperatures.
- the melt blending conditions are not particularly limited, however, for example, a twin screw extruder is used for blending at 200 to 270° C. for 1 to 5 minutes.
- the acid anhydride modified soft resin is a soft resin modified by an acid anhydride.
- a “soft resin” means a resin having a Young's modulus of not more than 100 MPa at room temperature.
- the soft resin include an olefin-based polymer, ethylene-based polymer, ethylene- ⁇ -olefin copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, and ethylene-propylene rubber.
- the compatibility with the modified ethylene-vinyl alcohol copolymer can be improved.
- the acid anhydride in the modified soft resin can be suitably selected to give an appropriate compatibility with the modified ethylene-vinyl alcohol copolymer, however, preferably, the amount of the acid anhydride is 0.1 to 2 percent by weight based on the weight of the modified soft resin.
- the acid anhydride modified soft resin includes an anhydrous maleate-modified ethylene- ⁇ -olefin copolymer.
- it is an anhydrous maleate-modified ethylene-propylene copolymer or ethylene-butene copolymer.
- These are commercially available and can be obtained as Tafmer® MP-0620 (anhydrous maleate-modified ethylene-propylene copolymer) and Tafmer® MP-7020 (anhydrous maleate-modified ethylene-butene copolymer) from Mitsui Chemicals, Inc.
- the gas barrier resin of the present invention may comprise other substances within a scope of not hampering the effect of the present invention.
- the gas barrier resin may be a mixture with a resin other than the modified soft resin such as poly(vinyl alcohol), ethylene-vinyl alcohol copolymer, polyamide, polyester, polyolefin, polystyrene, polyurethane resin, poly(vinylidene chloride), poly(vinyl chloride), polycarbonate, etc.
- additives blended into it may comprise additives blended into it in addition to the above ingredients such as carbon black, silica, and other fillers, vulcanizing or cross-linking agents, vulcanizing or cross-linking accelerators, various types of oils, anti-aging agents, and other various types of additives generally blended in for resin use and other rubber composition use.
- additives may be kneaded in by a general method to obtain a composition to be vulcanized or cross-linked.
- the amounts of these additives blended may be made the conventional general amounts so long as not running counter to the object of the present invention.
- the gas barrier resin of the present invention may be used as various gas barrier materials.
- the gas barrier resin of the present invention may be used for various molded articles.
- the shape of the molded article includes, but not limited to, a film shape, cylinder shape, etc.
- the shaping method is not particularly limited and common methods may be used.
- the gas barrier resin of the present invention can be made into a film using a T-die extruder, an inflation machine, etc., and the film may be suitably used as the inner liner of a pneumatic tire because of its superior gas barrier property, heat resistance, and bending fatigue resistance. Further, cylinder-shaped ones may be suitably used as hoses.
- gas barrier resin of the present invention (hereinafter also simply referred to as a “gas barrier resin”) can be laminated to a resin other than the gas barrier resin of the present invention (hereinafter also simply referred to as “another resin”) or an elastomer other than the gas barrier resin of the present invention (hereinafter also simply referred to as an “elastomer”) to form a laminate.
- another resin a resin other than the gas barrier resin of the present invention
- elastomer an elastomer other than the gas barrier resin of the present invention
- a laminate comprising a gas barrier resin layer and another resin and/or elastomer layer means either a two-layer laminate comprising a gas barrier resin layer and another resin layer, a two-layer laminate comprising a gas barrier resin layer and an elastomer layer, a three-layer laminate comprising a gas barrier resin layer, another resin layer, and an elastomer layer, a multi-layer laminate comprising one or more gas barrier resin layers and one or more other resin layers, a multi-layer laminate comprising one or more gas barrier resin layers and one or more elastomer layers, or a multi-layer laminate comprising one or more gas barrier resin layers, one or more other resin layers, and one or more elastomer layers.
- the other resins include a polyolefin, polyamide, polyester, polystyrene, polyurethane, polyvinylidene chloride, polyvinyl chloride, polyacrylonitrile, and polycarbonate.
- a polyolefin polyamide, polyester, polystyrene, polyurethane, polyvinylidene chloride, polyvinyl chloride, polyacrylonitrile, and polycarbonate.
- One among these may be used alone, or a mixture of two or more may be used.
- the elastomer includes a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer. One among these may be used alone, or a mixture of two or more may be used. Further, the other resin and elastomer may be blended together and used.
- layers (films) of each may be prepared and bonded with each other or a laminate may be prepared by coextrusion, however the latter is preferable.
- coextrusion commonly used methods may be used. For example, coextrusion inflation and coextrusion blowing may be used.
- a laminate comprising a layer of the gas barrier resin and a layer of another resin and/or an elastomer of the present invention may be used in various applications requiring a gas barrier property.
- pneumatic tires or hoses may be prepared using these laminates as air barrier layers.
- a commonly used method may be used. For example, when arranging an inner liner at an inner side of a carcass layer, the laminate of the present invention is placed on a tire forming drum in a cylindrical shape, a carcass layer, belt layer, tread layer, and other members made of unvulcanized rubber used in normal tire production are overlaid in that order, then the drum is pulled out to obtain a green tire. Next, this green tire is vulcanized in accordance with normal methods to produce the desired pneumatic tire.
- a hose may be prepared as follows. First, pellets of the gas barrier resin of the present invention are used to extrude a thermoplastic elastomer composition on a mandrel coated with a release agent in advance from a resin extruder by the cross-head extrusion method to thereby form an inner tube. Further, another gas barrier resin of the present invention or a general thermoplastic elastomer may be extruded on top of the inner tube to form an inner tube outer layer. Next, when necessary, an adhesive is applied on the inner tube by coating or spraying.
- a braiding machine is used to braid a reinforcing yarn or reinforcing steel wire on top of the inner tube.
- an adhesive is coated on top of the reinforcing layer for bonding with the outer tube, then a resin is extruded from a cross-head resin extruder in the same way as the gas barrier resin of the present invention or the other generally used thermoplastic elastomer composition to form an outer tube.
- the mandrel is removed, whereby a hose can be obtained.
- the adhesive coated on the inner tube or the reinforcing layer includes an isocyanate-based, urethane-based, phenol resin-based, resorcin-based, chlorinated rubber-based, and HRH-based adhesives, however isocyanate-based and urethane-based adhesives are particularly preferable.
- ethylene-vinyl alcohol copolymer As the ethylene-vinyl alcohol copolymer, EVAL-H171B having 38 percent by mole of structural unit (1) made by Kuraray Co., Ltd. was used, while as the alkyl polyether silane, three types of alkyl polyether silane of formula (5) were used:
- Comparative Example 1 is an unmodified ethylene-vinyl alcohol copolymer and Comparative Examples 2 and 3 are modified ethylene-vinyl alcohol copolymers prepared using 2 percent by mole and 4 percent by mole, respectively, of glycidol in place of alkyl polyether silane.
- Each modified ethylene-vinyl alcohol copolymer was continuously discharged from the extruder as strands, cooled with water, cut by a cutter into pellets, then shaped into a film by a T-die extruder (220° C.) to obtain a film having a thickness of 25 ⁇ m.
- the temperature dependency of the specific heat was measured by heat analysis (DTA or DSC), and the peak temperature was recorded as the melting temperature.
- anhydrous maleate-modified EPM (Tafmer® MP-0620 made by Mitsui Chemicals, Inc.) were added to 100 parts by weight of the modified ethylene-vinyl alcohol copolymer of Example 3 and melt kneaded to prepare a gas barrier resin.
- the resin had a bending fatigue number of 52000, melting temperature of 160° C., and air permeability coefficient of 32.
- Example 7 Other than the use of an unmodified ethylene-vinyl alcohol copolymer (EVAL-H171B made by Kuraray Co., Ltd. having an ethylene unit content of 38 percent by mole) in Example 7 in place of the modified ethylene-vinyl alcohol copolymer of Example 3, the gas barrier resin was prepared in the same manner as in Example 7. Upon evaluation, the resin had a bending fatigue number of 340, melting temperature of 161° C., and air permeability coefficient of 34.
- EVAL-H171B unmodified ethylene-vinyl alcohol copolymer made by Kuraray Co., Ltd. having an ethylene unit content of 38 percent by mole
- Example 7 From the evaluation results of Example 7 and Comparative Example 4, it is clear that using a modified ethylene-vinyl alcohol copolymer will result in a significant increase in bending fatigue resistance in comparison to the unmodified ethylene-vinyl alcohol copolymer.
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- Chemical & Material Sciences (AREA)
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- Polymers & Plastics (AREA)
- Health & Medical Sciences (AREA)
- Organic Chemistry (AREA)
- Medicinal Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Engineering & Computer Science (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Tires In General (AREA)
- Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
- Rigid Pipes And Flexible Pipes (AREA)
- Other Resins Obtained By Reactions Not Involving Carbon-To-Carbon Unsaturated Bonds (AREA)
Abstract
Ethylene-vinyl alcohol copolymers have superior gas barrier properties, but are inferior in bending fatigue resistance. The present invention improves bending fatigue resistance without reducing the gas barrier property and heat resistance. An ethylene-vinyl alcohol copolymer having an ethylene content of 20 to 50 percent by mole is modified by incorporating 0.01 to 1% mol of a structural unit expressed by the following formula (3):
wherein, n indicates an integer of 2 to 5, m indicates an integer of 10 to 20, and R1 indicates a C1 to C20 aliphatic hydrocarbon group provided that R1 may contain a mercapto group, thioester group, sulfenamide, vinyl group, methacryloxy group, or acryloxy group. The modified ethylene vinyl alcohol copolymer may be used as a gas barrier resin and this gas barrier resin may be shaped or laminated and used in various applications such as in pneumatic tires and hoses.
Description
- The present invention relates to a modified ethylene-vinyl alcohol copolymer, more particularly relates to a gas barrier resin comprising the modified ethylene-vinyl alcohol copolymer and a molded article prepared from the same, particularly a pneumatic tire and a hose.
- Ethylene-vinyl alcohol copolymers have superior gas barrier property, but have the defect that they are interior in bending fatigue resistance. To improve on this, there is known a method of modifying an ethylene-vinyl alcohol copolymer with an epoxy compound. See Japanese Unexamined Patent Publication No. 2003-231715.
- Technical Problem
- However, if modifying an ethylene-vinyl alcohol copolymer with an epoxy compound, the bending fatigue resistance will be improved, but the gas barrier property and heat resistance (melting point) will tend to drop. The present invention addresses the matter of improving the drawback of an ethylene-vinyl alcohol copolymer, that is, the bending fatigue resistance, without reducing gas barrier property and heat resistance.
- Solution to Problem
- The present invention is a modified ethylene-vinyl alcohol copolymer comprising 20 to 50 percent by mole of a structural unit (1) expressed by the following formula (1):
-
—CH2—CH2— (1) - a structural unit (2) expressed by the following formula (2):
- and 0.01 to 1 percent by mole of a structural unit (3) expressed by the following formula (3):
- wherein n indicates an integer of 2 to 7, m indicates an integer of 10 to 20, and R1 indicates a C1 to C20 aliphatic hydrocarbon group or aliphatic hydrocarbon group substituted with a mercapto group, thioester group, sulfenamide, vinyl group, methacryloxy group, or acryloxy group.
- The modified ethylene-vinyl alcohol copolymer is preferably prepared by melt blending an ethylene-vinyl alcohol copolymer with an alkyl polyether silane expressed by the following formula (4):
- wherein R2 is a methyl group or ethyl group, and R1, n, and m are the same as above.
- The present invention, further, is a gas barrier resin comprising the modified ethylene-vinyl alcohol copolymer.
- The gas barrier resin preferably contains 100 parts by weight of the modified ethylene-vinyl alcohol copolymer and 5 to 120 parts by weight of a soft resin modified by an acid anhydride.
- The present invention, further, is a molded article comprising the gas barrier resin.
- The present invention, further, is a laminate comprising a layer of the gas barrier resin and a layer of a resin and/or elastomer other than the gas barrier resin.
- The resin other than the gas barrier resin is preferably at least one resin selected from the group consisting of a polyolefin, polyamide, polyester, polystyrene, polyurethane, poly(vinylidene chloride), poly(vinyl chloride), polyacrylonitrile, and polycarbonate.
- The elastomer other than the gas barrier resin is preferably selected from the group consisting of a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer.
- The present invention is a pneumatic tire comprising the gas barrier resin or the laminate as an air barrier layer.
- The present invention, further, is a hose comprising the gas barrier resin or the laminate as an air barrier layer.
- The modified ethylene-vinyl alcohol copolymer of the present invention is superior in gas barrier property, heat resistance, and bending fatigue resistance. Because the modified ethylene-vinyl alcohol copolymer of the present invention is superior in gas barrier property, heat resistance, and bending fatigue resistance, it may be suitably used as a gas barrier resin and in molded articles, particularly pneumatic tires and hoses, requiring a gas barrier property.
- The modified ethylene-vinyl alcohol copolymer of the present invention comprises a structural unit (1), a structural unit (2), and a structural unit (3).
- The structural unit (1) is a so-called ethylene unit expressed by the following formula (1):
-
—CH2—CH2— (1) - The structural unit (2) is a so-called vinyl alcohol unit expressed by the following formula (2):
- The structural unit (3) is a structural unit, containing an alkyl polyether silyl group in the side chain, expressed by the following formula (3):
- where n indicates an integer of 2 to 7, preferably an integer of 4 to 6, more preferably 5, m indicates an integer of 10 to 20, preferably an integer of 11 to 18, more preferably an integer of 12 to 16, and R1 indicates an aliphatic hydrocarbon group having one to 20 carbon atoms, preferably 2 to 10 carbon atoms, more preferably 3 to 5 carbon atoms. However, R1 may contain a mercapto group, thioester group, sulfenamide, vinyl group, methacryloxy group, or acryloxy group. R1 is particularly preferably 3-mercaptopropyl.
- The modified ethylene-vinyl alcohol copolymer comprises 20 to 50 percent by mole, preferably 30 to 45 percent by mole, more preferably 35 to 40 percent by mole of the structural unit (1). If the content of the structural unit (1) is too low, there is a tendency for the bending fatigue resistance to be insufficient, and if too high on the other hand, there is a tendency for gas barrier property to become insufficient.
- The modified ethylene-vinyl alcohol copolymer comprises 0.01 to 1 percent by mole, preferably 0.03 to 0.5 percent by mole, more preferably 0.05 to 0.25 percent by mole of the structural unit (3). If the content of the structural unit (3) is too low, there is a tendency for the bending fatigue resistance to be insufficient, and if too high on the other hand, there is a tendency for gas barrier property to become insufficient.
- Other than the structural unit (1) and structural unit (3) of the structural units composing the modified ethylene-vinyl alcohol copolymer, there is preferably the structural unit (2). That is, the modified ethylene-vinyl alcohol copolymer preferably comprises 49.9 to 79 percent by mole of structural unit (2). However, the modified ethylene-vinyl alcohol copolymer may comprise structural units other than structural unit (1), structural unit (2), and structural unit (3) within a scope that does not hamper the effect of the present invention. Note that, the content of each structural unit in the modified ethylene-vinyl alcohol copolymer may be measured by NMR.
- The modified ethylene-vinyl alcohol copolymer is an ethylene-vinyl alcohol copolymer comprising the structural unit (1) and structural unit (2) modified by an alkyl polyether silane shown in formula (4):
- wherein R2 indicates a methyl group or ethyl group, and R1, n, and m are the same as above.
- The modified ethylene-vinyl alcohol copolymer may be prepared by melt blending the ethylene-vinyl alcohol copolymer and the alkyl polyether silane shown in formula (4). By blending an ethylene-vinyl alcohol copolymer comprising 20 to 50 percent by mole of the structural unit (1) and the alkyl polyether silane shown in formula (4) at a temperature greater than their melting temperatures, the alkyl polyether silane shown in formula (4) reacts by condensation with the OH groups of the ethylene-vinyl alcohol copolymer whereby the alcohol is removed and the structural unit (3) is formed. The blend ratio of the ethylene-vinyl alcohol copolymer and the alkyl polyether silane shown in formula (4) is, based on 100 moles of the total of the structural unit (1) and structural unit (2) of the ethylene-vinyl alcohol copolymer, 0.01 to 1 mole of the alkyl polyether silane shown in formula (4). The conditions for melt blending are not particularly limited so long as they are conditions in which the ethylene-vinyl alcohol copolymer and the alkyl polyether silane shown in formula (4) react to form the structural unit (3), but for example a twin screw extruder may be used for processing at 200 to 270° C. for 1 to 5 minutes.
- A commercial product may be used for the alkyl polyether silane shown in formula (4) or one may be synthesized. An example of a commercial product is the VP Si363 made by Evonik Degussa. Synthesis may be performed as follows. Inside a reaction container, a silane compound having a trialkoxysilyl group (for example, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane, vinyltriethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryioxypropyltriethoxysilane, 3-acryloxypropyltrimethoxysilane, and 3-acryloxytriethoxysilane) is added, dodecylbenzenesulfonic acid or other acid catalyst is added, and further 2 equivalents by mole of a polyoxyethylene alkyl ether (for example, polyoxyethylene lauryl ether, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, etc.) based on one equivalent by mole of the silane compound is added, and the mixture is reacted while being agitated at 10 to 100° C. temperature, preferably 20 to 60° C. temperature, for several hours under reduced pressure conditions, whereby an alkyl polyether silane is obtained.
- The gas barrier resin of the present invention comprises the modified ethylene-vinyl alcohol copolymer. The gas barrier resin of the present invention may be comprised of only the modified ethylene-vinyl alcohol copolymer, however, it may contain other substances within a scope that does not hamper the effect of the present invention. For example, the gas barrier resin of the present invention may be a mixture comprising, other than the modified ethylene-vinyl alcohol copolymer, an acid anhydride modified soft resin (hereinafter also referred to simply as a “modified soft resin”). That is, the gas barrier resin of the present invention may be a mixture of a modified ethylene-vinyl alcohol copolymer and modified soft resin. The inclusion of modified soft resin can further improve the bending fatigue resistance. The amount of the modified soft resin blended is, preferably, 5 to 120 parts by weight based on 100 parts by weight of the modified ethylene-vinyl alcohol copolymer. If the amount of the modified soft resin is too low, the improvement effect on the bending fatigue resistance will be lower, and if on the other hand, the amount of the modified soft resin is too high, there is a tendency for gas barrier property to become insufficient.
- The mixture of the modified ethylene-vinyl alcohol copolymer and the modified soft resin is preferably a melt blend of the modified ethylene-vinyl alcohol copolymer and the modified soft resin. The modified ethylene-vinyl alcohol copolymer and modified soft resin may be melt blended at a temperature greater than their melting temperatures. The melt blending conditions are not particularly limited, however, for example, a twin screw extruder is used for blending at 200 to 270° C. for 1 to 5 minutes.
- The acid anhydride modified soft resin is a soft resin modified by an acid anhydride. A “soft resin” means a resin having a Young's modulus of not more than 100 MPa at room temperature. Examples of the soft resin include an olefin-based polymer, ethylene-based polymer, ethylene-α-olefin copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, and ethylene-propylene rubber.
- By modifying the soft resin with an acid anhydride, the compatibility with the modified ethylene-vinyl alcohol copolymer can be improved. The acid anhydride in the modified soft resin can be suitably selected to give an appropriate compatibility with the modified ethylene-vinyl alcohol copolymer, however, preferably, the amount of the acid anhydride is 0.1 to 2 percent by weight based on the weight of the modified soft resin.
- The acid anhydride modified soft resin includes an anhydrous maleate-modified ethylene-α-olefin copolymer. Preferably, it is an anhydrous maleate-modified ethylene-propylene copolymer or ethylene-butene copolymer. These are commercially available and can be obtained as Tafmer® MP-0620 (anhydrous maleate-modified ethylene-propylene copolymer) and Tafmer® MP-7020 (anhydrous maleate-modified ethylene-butene copolymer) from Mitsui Chemicals, Inc.
- The gas barrier resin of the present invention, as mentioned above, may comprise other substances within a scope of not hampering the effect of the present invention. The gas barrier resin may be a mixture with a resin other than the modified soft resin such as poly(vinyl alcohol), ethylene-vinyl alcohol copolymer, polyamide, polyester, polyolefin, polystyrene, polyurethane resin, poly(vinylidene chloride), poly(vinyl chloride), polycarbonate, etc. Further, it may comprise additives blended into it in addition to the above ingredients such as carbon black, silica, and other fillers, vulcanizing or cross-linking agents, vulcanizing or cross-linking accelerators, various types of oils, anti-aging agents, and other various types of additives generally blended in for resin use and other rubber composition use. These additives may be kneaded in by a general method to obtain a composition to be vulcanized or cross-linked. The amounts of these additives blended may be made the conventional general amounts so long as not running counter to the object of the present invention.
- The gas barrier resin of the present invention may be used as various gas barrier materials.
- The gas barrier resin of the present invention may be used for various molded articles. The shape of the molded article includes, but not limited to, a film shape, cylinder shape, etc. The shaping method is not particularly limited and common methods may be used. The gas barrier resin of the present invention can be made into a film using a T-die extruder, an inflation machine, etc., and the film may be suitably used as the inner liner of a pneumatic tire because of its superior gas barrier property, heat resistance, and bending fatigue resistance. Further, cylinder-shaped ones may be suitably used as hoses.
- The gas barrier resin of the present invention (hereinafter also simply referred to as a “gas barrier resin”) can be laminated to a resin other than the gas barrier resin of the present invention (hereinafter also simply referred to as “another resin”) or an elastomer other than the gas barrier resin of the present invention (hereinafter also simply referred to as an “elastomer”) to form a laminate. A laminate comprising a gas barrier resin layer and another resin and/or elastomer layer means either a two-layer laminate comprising a gas barrier resin layer and another resin layer, a two-layer laminate comprising a gas barrier resin layer and an elastomer layer, a three-layer laminate comprising a gas barrier resin layer, another resin layer, and an elastomer layer, a multi-layer laminate comprising one or more gas barrier resin layers and one or more other resin layers, a multi-layer laminate comprising one or more gas barrier resin layers and one or more elastomer layers, or a multi-layer laminate comprising one or more gas barrier resin layers, one or more other resin layers, and one or more elastomer layers.
- The other resins include a polyolefin, polyamide, polyester, polystyrene, polyurethane, polyvinylidene chloride, polyvinyl chloride, polyacrylonitrile, and polycarbonate. One among these may be used alone, or a mixture of two or more may be used.
- The elastomer includes a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer. One among these may be used alone, or a mixture of two or more may be used. Further, the other resin and elastomer may be blended together and used.
- As a method of production of the laminate, layers (films) of each may be prepared and bonded with each other or a laminate may be prepared by coextrusion, however the latter is preferable. For the coextrusion, commonly used methods may be used. For example, coextrusion inflation and coextrusion blowing may be used.
- A laminate comprising a layer of the gas barrier resin and a layer of another resin and/or an elastomer of the present invention may be used in various applications requiring a gas barrier property. For example, pneumatic tires or hoses may be prepared using these laminates as air barrier layers.
- As a method for producing a pneumatic tire using the laminate of the present invention as an air barrier layer, a commonly used method may be used. For example, when arranging an inner liner at an inner side of a carcass layer, the laminate of the present invention is placed on a tire forming drum in a cylindrical shape, a carcass layer, belt layer, tread layer, and other members made of unvulcanized rubber used in normal tire production are overlaid in that order, then the drum is pulled out to obtain a green tire. Next, this green tire is vulcanized in accordance with normal methods to produce the desired pneumatic tire.
- As a method for producing a hose using the gas barrier resin of the present invention, a commonly used method may be used. For example, a hose may be prepared as follows. First, pellets of the gas barrier resin of the present invention are used to extrude a thermoplastic elastomer composition on a mandrel coated with a release agent in advance from a resin extruder by the cross-head extrusion method to thereby form an inner tube. Further, another gas barrier resin of the present invention or a general thermoplastic elastomer may be extruded on top of the inner tube to form an inner tube outer layer. Next, when necessary, an adhesive is applied on the inner tube by coating or spraying. Further, a braiding machine is used to braid a reinforcing yarn or reinforcing steel wire on top of the inner tube. When necessary, an adhesive is coated on top of the reinforcing layer for bonding with the outer tube, then a resin is extruded from a cross-head resin extruder in the same way as the gas barrier resin of the present invention or the other generally used thermoplastic elastomer composition to form an outer tube. Finally, the mandrel is removed, whereby a hose can be obtained. The adhesive coated on the inner tube or the reinforcing layer includes an isocyanate-based, urethane-based, phenol resin-based, resorcin-based, chlorinated rubber-based, and HRH-based adhesives, however isocyanate-based and urethane-based adhesives are particularly preferable.
- To prepare a modified ethylene-vinyl alcohol copolymer, as the ethylene-vinyl alcohol copolymer, EVAL-H171B having 38 percent by mole of structural unit (1) made by Kuraray Co., Ltd. was used, while as the alkyl polyether silane, three types of alkyl polyether silane of formula (5) were used:
- wherein n=5 and m=12 (hereinafter referred to as “alkyl polyether silane 1”), n=5 and m=16 (hereinafter referred to as “alkyl polyether silane 2”), and n=5 and m=18 (hereinafter referred to as “alkyl polyether silane 3”).
- The ethylene-vinyl alcohol copolymer and the alkyl polyether silane of the type and amount according to Table 1 were charged into a twin screw kneader (TEX44 made by Japan Steel Works) and melt kneaded at 230° C. for 3 minutes to obtain the modified ethylene-vinyl alcohol copolymer (Examples 1 to 6). Note that, Comparative Example 1 is an unmodified ethylene-vinyl alcohol copolymer and Comparative Examples 2 and 3 are modified ethylene-vinyl alcohol copolymers prepared using 2 percent by mole and 4 percent by mole, respectively, of glycidol in place of alkyl polyether silane.
- Each modified ethylene-vinyl alcohol copolymer was continuously discharged from the extruder as strands, cooled with water, cut by a cutter into pellets, then shaped into a film by a T-die extruder (220° C.) to obtain a film having a thickness of 25 μm.
- The following test methods were used to test the modified ethylene-vinyl alcohol copolymers.
- [Bending Fatigue]
- 50 sheets of the single layer films produced according to the above and cut into sizes of 21 cm by 30 cm were produced and, based on ASTM F 392-74, were bent 50 times, 100 times, 200 times, 250 times, 1000 times, 10000 times, 20000 times, 50000 times, 75000 times, and 100000 times, then measured for the number of pinholes using a Gelbo Flex Tester made by Rigaku Kogyo. At each number of bending times, measurement was performed five times and the average of these measurements was recorded as the number of pinholes. The measurement results were plotted with the number of bending times (P) as the abscissa and the number of pinholes (N) as the ordinate. The number of bending times to one pinhole was determined by extrapolation to 2 significant figures.
- [Melting Temperature]
- The temperature dependency of the specific heat was measured by heat analysis (DTA or DSC), and the peak temperature was recorded as the melting temperature.
- [Air Permeability Coefficient]
- Based on JIS K6404, samples were prepared and air permeability was measured at 60° C. The results were shown as values indexed to the value of the air permeability coefficient of Comparative Example 1 as 100. The greater the value, the more superior the gas barrier property.
- The obtained test results are shown in Table 1. It is clear that the bending fatigue resistance of the alkyl polyether silane-modified ethylene-vinyl alcohol copolymers (Examples 1 to 6) of the present invention increases significantly in comparison to the unmodified ethylene-vinyl alcohol copolymer (Comparative Example 1). Further, the bending fatigue resistance of the epoxy modified ethylene-vinyl alcohol copolymers of the prior art (Comparative Examples 2 and 3) is improved, but the heat resistance and gas barrier property drop, while the bending fatigue resistance of the alkyl polyether silane-modified ethylene-vinyl alcohol copolymers (Examples 1 to 6) of the present invention can be improved without reducing heat resistance and gas barrier property.
-
TABLE 1 Comp. Comp. Comp. Ex. 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 2 Ex. 3 Alkyl polyether 0.05 mol % 0.08 mol % 0.10 mol % 0.25 mol % silane 1 (n = 5, m = 12) Alkyl polyether 0.10 mol % silane 2 (n = 5, m = 16) Alkyl polyether 0.10 mol % silane 3 (n = 5, m = 18) Glycidol 2 mol % 4 mol % Bending fatigue 12 229 240 320 310 250 260 240 300 number Melting 161 160 160 160 160 160 160 151 145 temperature (° C.) Air permeability 100 95 94 94 96 98 96 85 75 - 80 parts by weight of anhydrous maleate-modified EPM (Tafmer® MP-0620 made by Mitsui Chemicals, Inc.) were added to 100 parts by weight of the modified ethylene-vinyl alcohol copolymer of Example 3 and melt kneaded to prepare a gas barrier resin. Upon evaluation, the resin had a bending fatigue number of 52000, melting temperature of 160° C., and air permeability coefficient of 32.
- Other than the use of an unmodified ethylene-vinyl alcohol copolymer (EVAL-H171B made by Kuraray Co., Ltd. having an ethylene unit content of 38 percent by mole) in Example 7 in place of the modified ethylene-vinyl alcohol copolymer of Example 3, the gas barrier resin was prepared in the same manner as in Example 7. Upon evaluation, the resin had a bending fatigue number of 340, melting temperature of 161° C., and air permeability coefficient of 34.
- From the evaluation results of Example 7 and Comparative Example 4, it is clear that using a modified ethylene-vinyl alcohol copolymer will result in a significant increase in bending fatigue resistance in comparison to the unmodified ethylene-vinyl alcohol copolymer.
Claims (20)
1. A modified ethylene-vinyl alcohol copolymer comprising 20 to 50 percent by mole of a structural unit (1) expressed by the following formula (1):
—CH2—CH2— (1)
—CH2—CH2— (1)
a structural unit (2) expressed by the following formula (2):
2. A modified ethylene-vinyl alcohol copolymer as set forth in claim 1 , wherein the modified ethylene-vinyl alcohol copolymer is prepared by melt blending an ethylene-vinyl alcohol copolymer with an alkyl polyether silane expressed by the following formula (4):
3. A gas barrier resin comprising a modified ethylene-vinyl alcohol copolymer as set forth in claim 1 .
4. A gas barrier resin as set forth in claim 3 , comprising 100 parts by weight of the modified ethylene-vinyl alcohol copolymer and 5 to 120 parts by weight of a soft resin modified by an acid anhydride.
5. A molded article comprising a gas barrier resin as set forth in claim 3 .
6. A laminate comprising a layer of a gas barrier resin as set forth in claim 3 and a layer of a resin and/or an elastomer other than the gas barrier resin.
7. A laminate as set forth in claim 6 , wherein the resin other than the gas barrier resin is at least one resin selected from the group consisting of a polyolefin, polyamide, polyester, polystyrene, polyurethane, poly(vinylidene chloride), poly(vinyl chloride), polyacrylonitrile, and polycarbonate.
8. A laminate as set forth in claim 6 , wherein the elastomer other than the gas barrier resin is selected from the group consisting of a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer.
9. A pneumatic tire comprising a gas barrier resin as set forth in claim 3 as an air barrier layer.
10. A hose comprising a gas barrier resin as set forth in claim 3 as an air barrier layer.
11. A pneumatic tire comprising a laminate as set forth in claim 6 as an air barrier layer.
12. A hose comprising a laminate as set forth in claim 6 as an air barrier layer.
13. A gas barrier resin comprising a modified ethylene-vinyl alcohol copolymer as set forth in claim 2 .
14. A molded article comprising a gas barrier resin as set forth in claim 4 .
15. A laminate comprising a layer of a gas barrier resin as set forth in claim 4 and a layer of a resin and/or an elastomer other than the gas barrier resin.
16. A laminate as set forth in claim 15 , wherein the resin other than the gas barrier resin is at least one resin selected from the group consisting of a polyolefin, polyamide, polyester, polystyrene, polyurethane, poly(vinylidene chloride), poly(vinyl chloride), polyacrylonitrile, and polycarbonate.
17. A laminate as set forth in claim 16 , wherein the elastomer other than the gas barrier resin is selected from the group consisting of a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer.
18. A laminate as set forth in claim 7 , wherein the elastomer other than the gas barrier resin is selected from the group consisting of a diene-based elastomer, urethane-based elastomer, olefin-based elastomer, and styrene-based elastomer.
19. A gas barrier resin as set forth in claim 13 , comprising 100 parts by weight of the modified ethylene-vinyl alcohol copolymer and 5 to 120 parts by weight of a soft resin modified by an acid anhydride.
20. A pneumatic tire comprising a gas barrier resin as set forth in claim 4 as an air barrier layer.
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US13/733,366 US8969475B2 (en) | 2008-08-25 | 2013-01-03 | Method for preparing a modified ethylene-vinyl alcohol copolymer |
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JP2008215517A JP4488097B2 (en) | 2008-08-25 | 2008-08-25 | Gas barrier resin molded product or laminate |
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US12/485,598 Abandoned US20100047586A1 (en) | 2008-08-25 | 2009-06-16 | Modified ethylene-vinyl alcohol copolymer, gas barrier resin, and molded article of the same |
US13/733,366 Expired - Fee Related US8969475B2 (en) | 2008-08-25 | 2013-01-03 | Method for preparing a modified ethylene-vinyl alcohol copolymer |
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EP (1) | EP2159234B1 (en) |
JP (1) | JP4488097B2 (en) |
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Cited By (4)
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US20130123428A1 (en) * | 2008-08-25 | 2013-05-16 | The Yokohama Rubber Col, Ltd. | Method for Preparing a Modified Ethylene-Vinyl Alcohol Copolymer |
US20150165586A1 (en) * | 2013-12-17 | 2015-06-18 | Fujibo Holdings, Inc. | Resin Lapping Plate and Lapping Method Using the Same |
US20160039247A1 (en) * | 2013-03-15 | 2016-02-11 | Bridgestone Americas Tire Operations, Llc | Light-Weight Inner Tube And Related Methods |
US20220186858A1 (en) * | 2019-03-11 | 2022-06-16 | Contitech Techno-Chemie Gmbh | Coolant hose |
Families Citing this family (5)
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JP5440249B2 (en) * | 2010-02-25 | 2014-03-12 | 横浜ゴム株式会社 | Modified ethylene-vinyl alcohol copolymer, process for producing the same, and gas barrier resin composition |
US9868267B2 (en) * | 2011-05-31 | 2018-01-16 | Bridgestone Corporation | Multilayer structure, inner liner for pneumatic tire, and pneumatic tire |
JP5911731B2 (en) * | 2012-02-14 | 2016-04-27 | 株式会社ブリヂストン | tire |
RU2582521C2 (en) | 2012-02-14 | 2016-04-27 | Бриджстоун Корпорейшн | Tyre |
JP6021442B2 (en) * | 2012-05-28 | 2016-11-09 | 横浜ゴム株式会社 | Pneumatic tire |
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US20160039247A1 (en) * | 2013-03-15 | 2016-02-11 | Bridgestone Americas Tire Operations, Llc | Light-Weight Inner Tube And Related Methods |
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Also Published As
Publication number | Publication date |
---|---|
JP4488097B2 (en) | 2010-06-23 |
KR20100024343A (en) | 2010-03-05 |
US20130123428A1 (en) | 2013-05-16 |
US8969475B2 (en) | 2015-03-03 |
CN101659724A (en) | 2010-03-03 |
ATE521644T1 (en) | 2011-09-15 |
CN101659724B (en) | 2013-08-07 |
JP2010047733A (en) | 2010-03-04 |
EP2159234A1 (en) | 2010-03-03 |
EP2159234B1 (en) | 2011-08-24 |
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